Cellular plastics containing saturated and unsaturated polyester resins



Patented June 16, 1953 CELLULAR PLASTICS RATED AND UNSATURATED POLYESTER RESINS CONTAINING SATU- Eli Simon, Los Angeles, and Frank W. Thomas, Burbank, Calif., assignors to Lockheed Aircraft Corporation, Burbank, Calif.

No Drawing. Application January 11', 1951, Serial No. 205,605

This invention relates to foamed or cellular plastic products and relates more particularly to cellular resin-polyester plastics incorporating both saturated and unsaturated polyester resins.

In certain copending applications such as Serial No. 77,058 filed February 17, 1949 now Patent No. 2,591,884 granted April 8, 1952 and Serial No. 194,934 filed November 9, 1950, we have disclosed cellular plastic compositions adapted to be foamed in place and that are prepared by mixing a polyisocyanate, a saturated polyester resin, a foam stabilizer, etc. and then pouring the resultant mixture into a cavity, mold, or the like, to react and foam up at atmospheric pressure. We

have found that we can produce a cellular or foamed plastic of controllable uniform cell size, of controllable density and that has excellent adhesion or bond strength when thus poured in place by employing a combination or mixture of saturated and unsaturated polyester resins in the isocyanate foaming system. We are aware that attempts have been made by others to employ unsaturated polyester resins in the production of foamed or cellular plastics by using compounds such as NH4HCO3 for liberating gas at elevated temperatures to form the cells but during the period in which the gas is being liberated the polymerization of the unsaturated polyester must be very carefully controlled by balancing the catalyst against an inhibitor to effectively utilize the gas being liberated and to prevent the collapse of the foam cells. We have attempted to prepare such unsaturated polyester resin foamed plastics with poor success, particularly where large volume sections or masses of the cellular plastic are required.

It is, therefore, an object of the present invention to provide for the production of cellular plastics of controlled uniform cellsize, controlled or selected density and of superior bond strength without depending upon or requiring a careful or delicate catalyst balance. We have discovered that the reaction between the saturated polyester and polyisocyanate as well as the reaction between the polyisocyanate and the unsaturated polyester resin serves to stabilize the foaming system to produce excellent uniformity in cell struc ture, density and strength. The polyester resins as utilized in the formulations of the present invention comprise blends, mixtures, or combinations of saturated and unsaturated polyesters in preferred or selected proportions and the polyisocyanate serves as a cross linking agent for the saturated polyester as well as being reactive with the unsaturated polyester primarily through its 14 Claims. (01. zoo-2.5)

free carboxyl and hydroxyl groups. Since the unsaturated polyester resin prior to cross linking with ethylenic-containing compounds, is essentially a linear polymer, it couples with the polyisocyanate through the terminal reactive groups serving to increasethe chain length without causing thermosetting of the resin. To obtain a cellular or foamed plastic product that is heat stable, we prefer to add unsaturated ethylenic-containing compounds that cross link with the unsaturated polyester resin by'addition polymerization in the presence of a peroxide type catalyst.

Another object of the invention is to'provide formulations for making cellular plastics of the class referred to that are relatively slow in reacting, thus permitting ample-time for mixing and pouring and that are quite fluid, thus facilitating the pouring of the reactant mixture. These characteristics materially extend the potential applications of the cellular products.

Still another object of the invention is to provide cellular plastics that have superior uniform ,as-foamed or as-poured bond strengths with practically all solids such as metals, fibre glasspolyester resin laminates, etc. and that are capable of transmitting micro wave energy, such as employed in radar, with a minimum of loss. These attributes well adapt the foams for use in radomes, aircraft control surfaces, and the like, where high strengths are required with or without the need for the tranmission of micro Wave energy.

Other objectives and advantages will become apparent from the following detailed description of typical preferred examples and of the manner of preparing the same.

The invention provides, generally, the preparation or mixing of a polyisocyanate, a saturated polyester resin, an unsaturated polyester resin, a catalyst, a monomer, a foam stabilizing agent and certain additives, if desired,and the pouring or application of this reactant mixture to react at normal room temperatures and atmospheric pressure with or without'a post-curing at somewhat elevated' temperatures.

'The polyisocyanate is preferably, though not necessarily, meta-toluene diisocyanate. The diisocyanate is used in the proportion of from 17 to partsby' weight for each parts by weight of the total resin (both saturated and unsaturated polyester resins) A preferred range is from 25 to 45 parts by weight of the meta-toluene diisocyanate for each 100 parts (total) of the resins. Excellent results are obtained when a high molecular weight thermoplastic film forming polyi 3 meric resin additive is employed with or added to the meta-toluenediisocyanate. The high molecular weightv polymeric resin additives that we have found to be useful include: ethyl cellulose, polymeric chlorinated natural rubber, beh'z'yl cellulose, natural rubber, polymeric vinyl chloadditive and the concentration of the additive .is I

somewhat dependent upon its respective viscosity.

For example, the polymeric chlorinated natural rubber may be used in the proportio s-r "from'5 to 20 grams "for each 100 grains of the iineta toluene di'i' 'byanajte and the benzyl cenui'ose and polymeric 'vihy1 hieriaewmm acetate copolymers may be employed 'in the proportion or from one-hair 1 /2) to 10. grams, foreach r grams or the l'llthlifillllle diiscyana'te. or

" specific applications we have roun "that ms, 4 .graimianu '6 ra ns respectively or the cellulose, "for each '100 ams or the. meta-toluene diisocyahate are v'aluablefin obtainingproducts of certain desiredfphysi'cal properties char-- acteristics. Ethyl cellulose "has been ."found to "be particularly advantageous in the formulations oi the invention. Satisiacto'ry results are obtained using commercial :lg'radesfo'f ethyl cellulose re's'iiis wherein the substitution values are between 2.15 and 2.60 ethoxyl groups 'for each Eluco'se unit, that is where the ,ethoxyl content is from 35% to 50%. A preferred ethoxylfconte'nt range of the ethyl cellulose resin is from 45.0 to 49.5%. The concentr-ation of the ethyl cellulose in the reactant, polyester resjinmeta-to luene diis'ocyanate vsys tems of the-invention is from 0.30 grain to grams of the ethyl cellulose for each 100 grains of themeta-toluene diisocyanate, a preferred concentration being between and 6 grams of the ethyl cellulose foreach 100 grains of the diisocyanate. The viscosity of the ethyl cellulose resins which we prefer to employ is between )7 and ZOQ centipoises and preferably between 50 and 100 .centipoises, the viscosity being determined from a' -5% by weight concentration of the ethyl cellulose "in a solution of fro'in 70 toBO .parts'by weight of toluene with from 30 to parts'by weight of thanol-dnaturedZB ethyl alcohol of 95% strength, the solution being at C. flhe above named high molecular weight thermoplastic -iilrn forming polymeric resin :additives aresoluble meta-toluene dii-socyana-te and may or may not react therewith and -their functions are toassist. in stabilizing the foam during the reaction,,permit the employmentof higher .wa-ter contents and to increase the -.ela'sticity "of the'cell walls during the foaming of the reactant mixture. I I

II The unsaturated resins employedinthe :cellular plastic formulations are polymerizable unsaturate'd alkyd r'e'sins. These resins ma y have an acid number 'of'from 25 to 60 and'the ratio of their hydroxyl groups 'to their'carboxyl groups is approximately 1 to 1 with preferablya slight excess of the 'hydroxyl groups. The following are formulae suitable 'fo'r the preparationof unermomasuei-esm additive, such as ethyl 4 saturated alkyd resins suitable for incorporation in the cellular'plastic producing reactant mixtures:

Resin I t c T 1 Mols Diethylene glycol 6.3 Fumaric acid 5 Sebacic acid 1 (-Acid number of from 25 to 60 and preferably approximately 45.)

Resin II I Mols Ethylene .glycol l; 5.2 Maleic anhydride 4 Adipic acid 1 (as-m mber of from 25 to 60 and preferably about 40.)

Resin III Mols Diethylene glycol -cc =e .l L l-l- -ll 1.1 Maleic anhydride l. vl

(Acid number of from 25 to 60 and preferably about 40.)

The saturated polyester resins which we pro-- for to employ may be defined as alkyd resins which, when catalyzed with a peroxide type cataly'st, will not cross link with vinyl type compounds such as styrene, methyl methacrylate and a'clylofiitfile to form a 'tliermos'etting polymer. The acid number of these resins may range between 10 and 60 and'the ratio of the hydroxyl groups to the 'carboxyl groups is approximately 2 to l in most cases. Theiollowin'g arel'ormula'e fors'aturate'd polyester resins which we have found to be satisfactory for use in tnereactant cellular plastic producing mixture of the inventi'on:

Adiplc 'acld "2 Phthalic anhydride e /2 (The acid "number is preferably between 15 and 20.)

Resin D Mol Q'xalicacid 2% Trimethylol propane lc- 4 mer acids-ll.- 1 (The acid number is preferably between 10 and 25.) v

Resin E Mols 'Oxalic acid '2 Trimethylol propane "Bit; Dimer acids (The acid number is I I I preferably between 10 and 25.)

Resin F Mols Trimethylol propane 4 Dimer acids Phthalic anhydride Adipic acid l (The acid number is preferably between 15 and 35.)

Resin G Mols Trimethylol propane 4 Dimer acids Phthalic anhydride /2 Adipic acid 2 (The acid number is preferably between 20 and 30.)

Resin H Mols Glycerol monorlcinoleate 3 Trimethylol propane 8 Adipic acid 5 /2 Monoethyl phosphoric acid 2 Phthalic anhydride l (The acid number is preferably from 10 to 2D.)

Resin I Mols Trimethylol propane l Dimer acids Phthalic anhydride 1 Adipic acid l (The acid number is preferably approxi mately 55.)

Resin J Mols Trimethylol propane e Dimer acids Phthalic anhydride l Adipic acid l (The acid number is preferably between and 30.)

Resin K Mols 'I'rimethylol propane 4 Dimer acids /2 Phthalic anhydride Adipic acid 1 /2 The ratio or proportion of the unsaturated alkyd resin to the saturated resin may be Varied considerably. In practice this ratio may be from parts by weight of the unsaturated resin to 60 parts by weight of the saturated resin; to 60 parts by Weight of the unsaturated resin to 20 parts by weight of the saturated resin. The preferred proportion is approximately 30 parts by weight of the unsaturated resin to approximately 30 parts by weight of the saturated resin. It should be observed that the meta-toluene diisocyanate-ethyl cellulose solutions may be used in practically all of the formulations.

The catalyst which we employ is of the peroxide type such as benzoyl peroxide, lauroyl peroxide and bis (zA-dichlorobenzoyl) peroxide. It has been found desirable in most instances to use benzoyl peroxide as the catalyst. The catalyst is used in the proportion of from to 5% by weight of the unsaturated polyester resin with the preferred proportion being approximately 2% of the unsaturated polyester resin.

The monomer or monomers which we incorporate in the reactant mixture are unsaturated ethylenic-containing compounds. The following have been found to be practical and effective as monomers: styrene, styrene-divinyl benzene mixtures, methyl methacrylate, butyl methacrylate, acrylonitrile, diallyl phthalate, diallyl benzene phosphcnate, vinyl acetate, glycol diacrylate, diallyl maleate, and methyl-chloroacrylate.

The amount or proportion of the monomer employed may range between 10 and 50 parts by weight for each parts by weight of the unsaturated polyester resin with the preferred range being between 20 and 40 parts by weight of the monomer for each 100 parts by weight of the unsaturated polyester.

The invention contemplates the inclusion in the reactant foam producing mixture of one or more additives which we will term foam stabilizers. We have found that several different classes or types of such additives are effective in facilitating the production of superior high strength, low density cellular plastics of substantially uniform cell size, such additives including quaternary ammonium bentonite complexes, metallic soap powders and metallic leafing powders. The hentonite complexes or salts are produced by the reaction of bentonite with organic bases or salts of organic bases through base exchange wherein the calcium, sodium, potassium, magnesium or other replaceable bases of the silicate of the bentonite enter into double decomposition with.

cations of organic bases. Such bentonite complexes are manufactured by the National Lead Company of New York, N. Y., and may be considered bentonite salts of quaternary ammonium compounds. In order to simplify their identification the bentonite complexes will be given the trade name Bentone with the numerals following the name Bentone designating the number of carbon atoms in the quaternary compounds from which the bentonite complex is derived. Thus Bentone'34 is a quaternary ammonium bentonite compound obtained through base exchange between bentonite and dimethyl dihexadecyl ammonium chloride. The bentonite salts of quaternary ammonium compounds which we have found to be efiective as foam stabilizers include:

1. Bentone 26-dimethyl didodecyl ammonium bentonite. f

2. Bentone 30- -dimethyl dodecyl hexadecyl ammonium bentonite.

3. Bentone 34-dimethyl dihexadecyl monium bentonite.

'4. Bentone 36-dimethyl hexadecyl octadecyl ammonium bentonite.

5. Bentone .38dimethyl monium bentonite.

The quaternary, ammonium radical of these didioctadecyl ammethyl alkyl quaternary ammonium complexes may be represented as follows:

the sum of the carbon atoms being between '26. and 38, and preferably between .30 and 36. This reaction may be descriptively portrayed as one of base exchange in the following:

where M represents a univalent cation such as sodium but may represent multivalent cationssuch as calcium, magnesium, or other replaceable bases of the silicate constituent of the bentonite. The Bentones or quaternary ammonium compounds or complexes maybe used individually or in suitable mixtures or blendsin the reactant polyisocyanate-polyester resin reactant mixtures in the proportion of from 1 to 10 parts by weight for each 100 parts by weight of the total resin content of the mixture,-a preferred range of proportions of the Bentones being between 1.5 and 5 parts by weight for each 100 parts by weight of the total saturated and unsaturated polyester resin content of the mixture. While each of the above named quaternary ammonium bentonite complexes are practi cal and effective as foam stabilizers, the best results have been obtained with Bentone '34- dimethyl dihexadecyl ammonium bentonite. With certain of the saturated alkyd resins employed in the formulations no foam stabilizers, such as the Ben-tones, metallic soaps, metallic leafing powders or high molecular Weight polymeric resin additives are required. These saturated polyester resins are oil modified and pertain particularly to Resins F, G, H, I, J, and K.

The above mentioned metallic soap powders suitable as foam stabilizer ingredients or addltives are metallic soap powders of fatty acids having from 12 to 20 carbon atoms such as: zinc stearate, aluminum stearate, calcium stearate, magnesium stearate, magnesium hydroxy stearate, barium stearate, zinc laureate, calcium oleate, and strontium stearate.

The proportion of the metallic soap powder or blends of metallic soap powder employed may range from 1 to 12, and preferably2' to 8 parts by weight for each 100 parts by weight of the total resin content of the reactant mixture. The metallic leafing powders which we have found to be eifective as foam stabilizers include: aluminum leafing powder, lead leafing' powder, nickel leafing powder, silver leafin'g powder, gold leafing powder, and stainless steel leafin'g powder.

These metallic leafing powders are employed individually or in suitable mixtures or combinations in the proportion of from 1 to 12 and preferably 2 to 8 parts by weight for each 100' parts by weight of the total resin content of the reactant mixture. Good. results are. obtained. when both a metallic l'eafin'g powder and a metallic soap powder are incorporated in the polyisocyanate-alkyd resin mixture. Such a combination of foam stabilizing additives appears to act' synergistically, thatiis: the: combination causes the foamation of a greater volume of the cellular plastic than if the same proportionate quantity of each individual filler is used separately in the identical polyisocyanate-alkyd resin reactant mixture; When both the metallic leafing powder and metallic soap powder are used the metallic leafing powder may be employed in the proportion of from A to 8 parts by weight for each parts by weight of the total resin content and the metallic soap powder may be used in the proportion of from to 8 parts by Weight for each 100 parts by weight of the total resin content.

The water. content of the reactant mixtures may range from 0.25% to 4% by weight based on the resincontent of the mixture.

The following are typical examples of the formulations of the invention for producing the foamed or cellular alkyd resin polyisocyanate reaction products.

Example 1 Grams Resin I having an acid number of from 35 to 45 30 Resin A having an acid number of 15 to 25- 3% water content -l- 30 Benzoyl peroxide A Styrene 9 Meta-toluene diisocyanate containing 2 parts by Weight of ethyl cellulose having a viscosity of 100 centipoises and an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the meta-toluene diisocyanate 20 Example 2 Grams Resin I having an acid number of 50 30 Resin A having an acid number of 18-4% water content 30 Benzoyl peroxide 0.75 Styrene 9 Meta-toluene diisocyanate containing 6 parts by weight ethyl cellulose having a viscosity of 100 centipo-ises and an ethoxy content of from 46.8 to 48.5% for each 100 parts by Weight of the meta-toluene diisocyanate 30 Example 3 Grams Resin I having an acid number of 45---- 30 Resin A having an acid number of 18- 15% water content 30 Benzoyl peroxide /2 Methyl methacrylate 9 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of 100 centipoises and an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the metatoluene diisocyanate 25 Example 4 Grams Resin I having an acid. number of- 49 60 Resin A having an acid number of 18-l% water content 30 Diallyl benzene phosphona-te 12 Meta-toluene diisocyanate containing 2 parts by Weight of ethyl cellulose having a viscosity of 100 centipoises and an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the metatoluene diisocyanat'e -sl-l 2O Benzoyl peroxide -2--- 0.6

Example Grams Resin I having an acid number of 35 60 Resin A having an acid number of 18 water content 30 Styrene 18 Benzoyl peroxide 2 Meta-toluene diisocyanate containing 2 parts by Weight of ethyl cellulose of 100 centipoises viscosity and an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the meta-toluene diisocyanate 20 Example 6 Grams Resin I having an acid number of 45 30 Resin A having an acid number of 18-2% water content 30 Styrene 5 Methyl methacrylate 5 Benzoyl peroxide V2 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose of 100 centipoises viscosity and having an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the meta-toluene diisocyanate 20 Example 7 Grams Resin I having an acid number of 49 3O Resin A having an acid number of 18-3% Water content 30 Styrene 9 Benzoyl peroxide /2 Divinyl benzene 1 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of 100 centipoises and an ethoxy content of from 46.8 to 48.5% for each 100 parts by weight of the metatoluene diisocyanate" 20 Example 8 Grams Resin I having an acid number of from 35 to 45 30 Resin A having an acidnumber of from 15 to 25 and having a 4% Water content 30 Styrene 9 Benzoyl peroxide Bentone 34 2 Meta-toluene diisocyanate (If desired the formulation of Example 8 may be modified by employing 25 grams of the meta-toluene diisocyanate and 3 grams of the Bentone 34.)

Example 9 tGrams Resin I having an acid number of from 35 to 49 30 Resin F having an acid number of from 15 to 35 30 Water 1.0 Benzoyl peroxide tyrene 9 Meta-toluene diisocyanate containing 2 parts by Weight of ethyl cellulose having a. viscosity of 100 centipoises and. an ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the metatoluene diisocyanate 20 Example 10 Grams Resin I having an acid number of from 35 to 49"-; 30 Resin F having an acid number of from 20 130 30 30 Water 0.3 Benzoyl peroxide Styrene 9 Bentone 34 2 Meta-toluene diisocyanate 20 Example 11 Grams Resin I having an acid number of from 35 to 49 -l 30 Resin F having an acid number of 30 30 Water 0.4 Benzoyl peroxide Meta-toluene diisocyanate 20 Styrene 9 Example 12 Grams Resin I having an acid number of from 35 to 49 30 Resin G having an acid number of from 20 to 30 3O Styrene 9 Water 0.6 Benzoyl peroxide 0.5 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of centipoises and an ethoxy content of from 48.0 to "49% for each 100 parts by weight of the meta-toluene diisocyanate 20 Example 13 a Gram-s Resin I having an acid number of from 35 to 49 30 Resin G having an acid number of 28 30 Water 0.4 Benzoyl peroxide 1 Bentone 34 l Styrene 9 Meta-toluene diisocyanate 25 Example 14 Grams Resin II having an acid number of 35 30 Resin F having an acid number of 30 30 Water 0.5

Benzoyl peroxide 0.75 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of 100. centipoises and an ethoxy 7 .content of from 48.0 to 49.5% for each 100 parts by weight of the meta-toluene Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of 100 centipoises and an'ethoxy content of from 48.0 to 49.5% for each 100 parts by weight of the meta-toluene diisocyanate 11 Example 16 Grams Resin III having an acid number of S 30 Resin H having an acid number of 1% water content 30 Styrene 9 Benzoyl peroxide /2 Meta-toluene diisocyanate containing 2 parts by weight of ethyl cellulose having a viscosity of 100 centipoises and an ethoxy content of from 48.0. to 49.5% for each 100 parts by weight of the meta-toluene diisocyanate Example 17 I Grams Resin I havingan acid number of 49 Resign A having an acid number of 18-1 water content Benzoyl peroxide /z' Styrene' 9 Zinc stearate soap powder 3 Meta-toluene diisocyanate -r 20 (The formulation of Example 17 may be modified by employing aluminum leafing powder instead of the zinc stearate soappowder in the same proportion.)

Example 18 Grams Resin I having an acid number of 49 30 Resin F having an acid number of 30- 30 Water 0.4 Benzoyl peroxide /g Styrene V 9 Aluminum leafing powder 2 Meta-toluene diisocyanate 25 Example 19- Grams Resin I having an acid number of 49 30 Resin G having an acid number of 28 30 Water 7.0.4 Benzoyl peroxide I e Styrene 9 Aluminum leafing powder 1 Meta-toluene diisocyanate 25 Example-20 e w I J ""Grams Resin I (One) having an acid number of 49,- 30 Resin I having an acid number of 57; 30 Styrene 9 Water 0.7 BenZoyl peroxide Meta-toluene diisocyanate containing 2' parts by weight of ethyl cellulose having a viscosity of 10:0 cent'ipois'es and an ethoxy content' of from 48.0 to 495% for; each 100 parts by" weight'oi the meta-toluene diisocyanate 20 Example 21 Grams Resin I (One) having an acid number of 36 30 Resin I having an acid number of 55 30 Styrene 9 Water .I;;: Q '06 Benzoyl peroxide Meta-toluene diisocyanate, e-..-- 20 Example 22 Grams Resin II (two) having an acid number of 30 Resin 1', having an acid number of 59 30 Styrene 9 Water 0.4 Lauroyl peroxide /2 Meta-toluene diisooyanate '..M ,l 20

Example 2.3 Grams Resin I, having an acid number oi 30 Resin A, having an acid number of: 18-2% water content 30 Lauroyl peroxide v Styrene 9 Meta-toluene diisocyanate containing 2 parts by Weight of'ethyl cellulose having an ethoxy content of 48.0 to 49 .5% and a viscosity of 10.0 centipoises, for each. 100 parts by weight of the meta-toluene diisocyanate 20 Example 24 Grams Resin I (one) having an acid number of 30 Resin I having an acid number of 30 Styrene. 9 Water I 0.6 Bis (2,.-dichlorobenzoyl). peroxide Meta-toluene diisocyanate 20 Example 25 Grams Resin III having an acidnuimber of 35 -r 20 Resin Ihaving an acid number of 4.0 Styrene -7- 6 Water 0.3 Benzoyl peroxide Lauroyl peroxide Meta-toluene diisocyanate 20 Example 26 Grams Resin I having an acid number of from 35 to 45 v 23 Resin A having an acid number of 18-2 /2 water content 40 Styrene 'l Benzoyl peroxide Bentone 3d 2 Metatoluene diisocyanate 25 Example 27 Grams Resin I having an acid number of 42 30 Resin A having an acid number of 1 water content 30 Styrene 9 Bentone 34 3 Aluminum leafing powder 3 Benzoyl peroxide l Meta-toluene diisooyanate 25 In preparing the reactant mixtures the ingredients are simply thoroughly mixed together and the mixture is then poured in place or otherwise applied. The poured or applied mixture is then allowed to react at atmospheric pressure either with or without the application of external heat or attended by a moderate-heating of say between and F. depending upon the size of the batch. The mixture is allowed to react and the reaction is allowed to go on to completion to produce the foamed cellular plastic'pr'oduct. A postcuring at temperature of from 120 to 250 F. and for up to 24 hours may be desirable although in other cases the exothermic heat is all that is required.

, It should be understood that the invention is not based upon or dependent upon the theories which we have expressed. Nor is the invention to be regarded as limited to the express procedure or materials set forth, these details bein given only by way of illustration and to aid in clarifying the invention. We do not regard such specific details as essential to the invention except s ar s t y are expressed by way of limita- -13 tion in the following claims in which it is our intention to claim all. novelty inherent in the invention as broadly as is permissible in view of the prior art.

We claim:

1. The cellular plastic material which is the reaction product, in parts by weight of, 30 parts of an unsaturated polyester resin. prepared fror approximately 6.3 mols diethylene glycol, mols fumaric acid and 1 mol sebacic acid and having an acid number of from 25 to 60, 30 parts of a saturated polyester resin having an acid number of from to 25 prepared from approximately 4 mols trimethylol propane, 2.5 mols adipic acid and A; mol phthalic anhydride, the resins having a water content of approximately l /2% or" the total weight of the two resins, 9 parts of styrene, /2 part of benzoyl peroxide, and parts of metatoluene diisocyanate containing 2 parts by weight of ethyl cellulose for each 100 parts by weight of the meta-toluene diisocyanate, the ethyl cellulose having an ethoxy content of from 48.0 to 49.5% by weight and a viscosity of 100 centipoises as determined from a 5% by weight concentration in a solution of from 70 to 80 parts by weight of toluene with from 30 to 20 parts by weight of denatured 2B ethyl alcohol of 95% strength, the solution being at approximately C.

2. The cellular plastic material which is the reaction product, in parts by weight of, parts of an unsaturated polyester resin prepared from approximately 6.3 mols diethylene glycol, 5 mols fumaric acid and 1 mol sebacic acid and havin an acid number of from to 45, 30 parts of a saturated polyester resin having an acid number of from 15 to 25 prepared from approximately 4 mols trimethylol propane, 2.5 mols adipic acid and A2 mol phthalic anhydride, the resins having a water content of approximately 2% of the total wei ht of the two resins, 9 parts of styrene, /z part of benzoyl peroxide, 2 arts dimethyl dihexadecyl ammonium bentonite, and 20 parts metatoluene diisocyanate.

3. The cellular plastic material which is the reaction product, in parts by weight of, 30 parts of an unsaturated polyester resin prepared from approximately 6.3 mols diethylene glycol, 5 mols fumaric acid and 1 mol sebacic acid and having an acid number of from 35 to 49, 30 parts of a saturated. resin having an acid number of from 20 to 30 prepared from 4 mols trimethylol propane, mol phthalic anhydride, /2 mol of dimerized linoleic acids and 2 mols adip-ic acid, 9 parts styrene, 0.6 part water, 0.5 part benzoyl peroxide, and 20 parts meta-toluene diisocyanate containing 2 parts by weight for each 100 parts by weight of the meta-toluene diisocyanate of ethyl. cellulose having an ethoxy content of from 48.0 to 49.5% by weight and a viscosity of 100 centipoises as determined from a 5% by weight concentration in a solution of from '70 to 80 parts by weight of toluene with from 30 to 20 parts by weight of denatured 2B ethyl alcohol of 95% strength, the solution being at approximately 25 C.

4. The cellular plastic reaction product of, in approximate parts by weight, a polymerizable unsaturated polyester resin containing a plurality of ethylenic groups derived from alpha, betaethylenically unsaturated dicarboxylic acids having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerlzation catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said resins being in the proportion range of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25 to 4.0% by weight of the total weight of the resins, an organic peroxide polymerization catalyst in the proportion of from to 5% by weight of the unsaturated resin, from 10 to 50 parts of a polymerizable ethylenically-unsaturated monomer for each 100 parts of said unsaturated resin, and from 17 to parts of meta-toluene diisocyanate for each 100 parts of the total combined resins, said meta-toluene diisocyanate containing from 0.03 to 15 parts ethyl cellulose for each 100 parts of the metatoluene diisocyanate, the ethyl cellulose having an ethoxyl content of from 45.0 to 49.5% and a viscosity of 100 centipoises as determined from a 5% by weight concentration in a solution of from '70 to 80 parts by weight of toluene with from 30 to 20 parts by weight of denatured 2B ethyl alcohol of strength, the solution being at approximately 25 C.

5. The cellular plastic reaction product of, in approximate parts by weight, an unsaturated polyester derived from a dihydric alcohol and an alpha, beta-ethylenically unsaturated dicar boxylic acid and having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to carboxyl groups 0f the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said. resins being in the proportion range of from 20'parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25 to 4% by weight of the total weight of the resins, benzoyl peroxide in the amount of from to 5% by weight of the unsaturated resin, from 10 to 50 parts for each parts of said unsaturated resin of a monomer selected from the group con sisting of styrene, methyl methacrylate, butyl methacrylate, acrylonitrile, diallyl phthalate, diallyl benzene phosphonate, vinyl acetate, glycol diacrylate, diallyl maleate, methyl-chloro acrylate, styrene-divinyl benzene mixtures, from 1 to 10 parts for each 100 parts of the total resin content of a foam stabilizer selected from the group consisting of dimethyl didodecyl ammonium bentonite, dimethyl dodecyl hexadecyl ammonium bentonite, dimethyl dihexadecyl ammonium bentonite, dimethyl dihexadecyl ammonium bentonite, dimethyl hexadecyl octadecyl ammonium bentonite, dimethyl dioctadecyl ammonium bentonite, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts of the total resin content.

6. A foam product obtained by the reaction of, in approximate parts by weight, a polymerizable unsaturated polyester containing a plurality of ethylenic groups derived from alpha, betaethylenically unsaturated dicarboxylic acids and having an acid number of from 25 to 69 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to l, a saturated polyester resin of the class whichv when catalyzed with an organic perodixe, polymerization catalyst will not seam cross link with polymerizable ethylenicallyi-unsaturated compounds to form the thermosetting polymers, said resins being in the proportion. of from 20 parts of the unsaturated resin to 60 parts of the saturated. resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, an organic peroxide polymerization catalyst in the proportion of from to 5% by weight of the unsaturated resin, from to 50 parts of polymerizable ethylenically unsaturated monomer for each 100. parts Of the unsaturated resin, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts of the total combined resins.

7. A foam product obtained by the reaction of, in approximate parts by Weight, an unsaturated polyester derived from a dihydric alcohol and an alpha. betaethylenica1ly unsaturated dicarboxylic acid having an acid number of from to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, a catalyst in the proportion of from to 5% by weight of the unsaturated. resin selected from the group consisting of benzoyl peroxide, lauroyl peroxide, bis (2,4 dichlorobenzoyl) peroxide, from 10 to 50 parts of an unsaturated ethylenic-containing monomer for each 100 parts of the unsaturated resin selected from. the group consisting of styrene, methyl methacrylate, butyl methacrylate, acrylonitrile, diallyl phthalate, diallyl benzene phosphonate, vinyl acetate, glycol diacrylate, diallyl maleate, methylchloro acrylate, styrenedivinyl benzene mixtures, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts of the total combined resins.

8. A foam product obtained by the reaction of, in approximate parts by weight, a polymerizable unsaturated polyester resin containing a plurality of ethylenic groups derived from alpha, beta-ethylenically unsaturated dicarboxylic acids and having an acid number of from 25.to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst Will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, Water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, a catalyst in the proportion of from to 5% by weight of the unsaturated resin selected from the group consisting of benzoyl peroxide, lauroyl peroxide, bis (2,4- dichlorobenzoyl) peroxide, from 10 to 50 parts of a polymerizable ethylenically-unsaturated monomer for each 100 parts of the unsaturated resin, and from 17 to 80 parts of meta-toluene diisol6 cyanate for each 100 parts of the total combined resins.

' 9. A foam product obtained by the reaction of, in approximate parts by Weight, an unsaturated polyester derived from a dihydric alcohol and an alpha, beta-ethylenically unsaturated dicarboxylic acid having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an or ganic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form the thermosetting polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, a peroxide catalyst in the proportion of from /2 to 5% by weight" of the unsaturated resin selected from the group consisting of benzoyl peroxide, lauroyl peroxide, bis (2,4 dichlorobenzoyl) peroxide, from 10 to 50 parts of a polymerizable ethylenically-unsaturated monomer for each 100 parts of the unsaturated resin, from 1 to 10 parts of a quaternary ammonium salt of bentonite for each 100 parts of the total resin content, and from 17 to parts of meta-toluene diisocyanate for each parts of the total combined resins.

10. A foam product obtained by the reaction of, in approximate parts by weight, a polymer izable unsaturated polyester containing a plurality of ethylenicgroups derived from alpha, beta-ethylenically unsaturated dicarboxylic acids and having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to l, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of thesaturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, a catalyst in the proportion of from K to 5% by weight of the unsaturated resin selected from the group consisting of benzoyl peroxide, lauroyl peroxide, bis (2,4 dichlorobenzoyl) peroxide, from 10 to 50 parts of ethylenically-unsaturated monomer for each 100- parts of the unsaturated resin, from 1 to IO'parts for each 100 parts of the total resin content of a foam stabilizer selected from the group consisting of dimethyl didodecyl ammonium bentonite, dimethyl dodecyl hexadecyl ammonium bentonite, dimethyl dihexadecyl ammonium bentonite, dimethyl hexadecyl octadecyl ammonium bentonite, dimethyl dioctadecyl ammonium bentonite, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts of the total combined resins,

11. A foam product obtained by the reaction 01', in approximate parts by weight, a polymerizable unsaturated polyester containing a plurality of ethylenic groups derived from alpha, betaethylenically unsaturated dicarboxylic acids and having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to l, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosettin polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, a catalyst in the proportion of from to 5% by weight of the unsaturated resin selected from the group consisting of benzoyl peroxide, lauroyl peroxide, bis (2,4 dichlorobenzoyl) peroxide, from to 50 parts of a polymerizable ethylenically-unsaturated monomer for each 100 parts Of the unsaturated resin, from 1 to 12 parts for each 100 parts of the total resin content of metallic soap powders selected from the group consisting of zinc stearate, aluminum stearate, calcium stearate, magnesium stearate, magnesium hydroxy stearate, barium stearate, zinc laurate, calcium oleate, strontium stearate, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts of the total combined resins.

12. A foam product obtained by the reaction of, in approximate parts by weight, a polymerizable unsaturated polyester containing a plurality of ethylenic groups derived from alpha, betaethylenically unsaturated dicarboxylic acids and having an acid number of from 25 to 60 and wherein the ratio of the hydroxyl groups to the carboxyl groups of the alkyd reactants is approximately 1 to 1, a saturated polyester resin of the class which when catalyzed with an organic peroxide polymerization catalyst will not cross link with polymerizable ethylenically-unsaturated compounds to form thermosetting polymers, said resins being in the proportion of from 20 parts of the unsaturated resin to 60 parts of the saturated resin to 60 parts of the unsaturated resin to 20 parts of the saturated resin, water in the proportion of from 0.25% to 4.0% by weight of the total weight of the resins, an organic peroxide polymerization catalyst in the proportion of from to 5% by weight of the unsaturated resin, from 10 to 50 parts of ethylenically-unsaturated monomer for each 100 parts of the unsaturated resin, from 1 to 12 parts for each 100 parts of the total resin content of a metallic leafing powder selected from the group consisting of aluminum leafing powder, lead leafing powder, nickel leafing powder, silver leafing powder, gold leafing powder, stainless steel leafing powder, and from 17 to 80 parts of meta-toluene diisocyanate for each 100 parts Of the total combined resins.

13. The cellular foamed reaction product in approximate parts by weight of, 30 parts of an unsaturated polyester resin prepared from approximately 6.3 mols diethylene glycol, 5 mols fumaric acid and 1 mol sebacic acid and having an acid number of from 35 to 49, 30 parts of a saturated polyester resin having an acid number of from 15 to 35 prepared from approximately 4 mols trimethylol propane, /2 mol dimerized linoleic acids, 4; mol phthalic anhydride, 1 mol adipic acid, 1 part water, part benzoyl peroxide, 9 parts styrene, and 20 parts meta-toluene diisocyanate containing 2 parts for each 100 parts of the meta-toluene diisocyanate of ethyl cellulose having an ethoxy content of from 48.0 to 49.5% and having a viscosity of approximately 100 centipoises as determined from a 5% by weight concentration in a solution of from to parts by weight of toluene with from 30 to 20 parts by weight of denatured 2B ethyl alcohol of strength, the solution being at approximately 25 C.

14. The cellular foamed reaction product in approximate parts by weight of, 30 parts of an unsaturated polyester resin prepared from approximately 6.3 mols diethylene glycol, 5 mols fumaric acid and 1 mol sebacic acid and having an acid number of from 35 to 49, 30 parts of a saturated polyester resin having an acid number of approximately 28 prepared from approximately 4 mols trimethylol propane, /2 mol dimerized linoleic acids, /2 mol phthalic anhydride, and 2 mols adipic acid, 0.4 part water, part benzoyl peroxide, 1 part dimethyl dihexadecyl ammonium bentonite, 9 parts styrene, and 25 parts metatoluene diisocyanate.

ELI SIMON. FRANK W. THOMAS.

No references cited. 

6. A FOAM PRODUCT OBTAINED BY THE REACTION OF, IN APPROXIMATE PARTS BY WEIGHT, A POLYMERIZABLE UNSATURATED POLYESTER CONTAINING A PLURALITY OF ETHYLENIC GROUPS DERIVED FROM ALPHA, BETAETHYLENICALLY UNSATURATED DICARBOXYLIC ACIDS AND HAVING AN ACID NUMBER OF FROM 25 TO 60 AND WHEREIN THE RATIO OF THE HYDROXYL GROUPS TO THE CARBOXYL GROUPS OF THE ALKYD REACTANTS IS APPROXIMATELY 1 TO 1, A SATURATED POLYESTER RESIN OF THE CLASS WHICH WHEN CATALYZED WITH AN ORGANIC PERODIXE POLYMERIZATION CATALYST WILL NOT CROSS LINK WITH POLYMERIZABLE ETHYLENICALLY-UNSATURATED COMPOUNDS TO FORM THE THERMOSETTING POLYMERS, SAID RESINS BEING IN THE PROPORTION OF FROM 20 PARTS OF THE UNSATURATED RESIN TO 60 PARTS OF THE SATURATED RESIN TO 60 PARTS OF THE UNSATURATED RESIN TO 20 PARTS OF THE SATURATED RESIN, WATER IN THE PROPORTION OF FROM 0.25% TO 4.0% BY WEIGHT OF THE TOTAL WEIGHT OF THE RESINS, AN ORGANIC PEROXIDE POLYMERIZATION CATALYST IN THE PROPORTION OF FROM 1/2 TO 5% BY WEIGHT OF THE UNSATURATED RESIHN, FROM 10 TO 50 PARTS OF POLYMERIZABLE ETHYLENICALLY UNSATURATED MONOMER FOR EACH 100 PARTS OF THE UNSATURATED RESIN, AND FROM 17 TO 80 PARTS OF META-TOLUENE DIISOCYANATE FOR EACH 100 PARTS OF THE TOTAL COMBINED RESINS. 